ML19329F306
| ML19329F306 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 03/05/1976 |
| From: | Howell S CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| To: | James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| Shared Package | |
| ML19329F305 | List: |
| References | |
| HOWE-42-76, NUDOCS 8006250384 | |
| Download: ML19329F306 (5) | |
Text
_m i
/
n-
/
i 00:5!Hi10iS
^
\\j
.' t e s...,;.. U;
{a*,s :. m r.d ;'.:.:..,
stephen H. Howell v.co ereuene Generas Ofqces: 212 West Micm. gen Avenue Jackson. M CNQan 49201 March 5,1976 Hove-42-76 Mr. J. G. Keppler, Regional Director Office of Inspection and Enforce =ent US Nuclear Regulatory Cc==ission Region III 799 Roosevelt Read Glen Ellyn, IL 60137 MIDIADD NUCLEAR FIA:IT - NRC IIIMS OF NONCCMPLIA' ICE -
INSFICTION REPORT NO. 76 DOCKETS NOS. 50-329 Am 50-330 (V Tnis is in response to your letter dated February 3, 1976, which included the
)
results of your inspection of the Midland construction site en January 13-16, 1976 and which required cur reply.
Attached is the infer =ation replying to ycur stated requirements as to th'e three ite=s of ncnce=pliance cited in your inspection repert. In additien to the specific and definitive actions therein reper:ed en the particular ite=s in question, I have perscnally reviewed the situation in detail with both =y Project and C,uality Assurance organizations as well as with both Project and Quality Assurance persennel of 3echtel. At these =eetings, we critically analyced the situation and =ade =cves to bolscer any pctential weaknesses.
This was discussed with your personnel at a =eeting with the= in Jackscn en February 4,1976 and repcrted in their notes of the =eeting o-ith us.
I feel bound to point out =y feelings that the items of nonec=pliance &c=
this inspection have been classified in a too severe categcry. In reviewing your criteria for categories of nonec=pliance issued en Dece=ber 31, 1974, I do not believe that the items of nonce =pliance, which you have classified as " Infractions," are of a deg ee co= parable to the criteria or exa=ples listed for Infractions but =cre properly fit the " Deficiency" category.
I wish to assure you, however, that we take very seriously cur responsibilities to atte=pt to prevent any items of nonconfer=ance no u tter how =inor.
n 8006250 N I
CONSUMERS POWER COMPANY RESPONSE TO THREE ITEMS OF NONCOMPLIANCE DESCRIBED IN NBC INSPECTION REPORT #76-01 I.
DRYING OVEN TD4PERATURE VERIFICATION A.
Descrintionsor the Noncomeliance (1) From Pa6e 2 of Inspection Report #76-01:
" Contrary to 10 CFR Part 50, Appendix B, Criterion XII, a drying oven used in concrete testing activities had not been calibrated to assure temperature limits were not exceeded."
(2)
From Page 8 (Item No. 6) of Inspection Report #76-01:
"During the inspection, a drying oven for the aggregate was found without i
tec:perature verification record.
- he drying temperature acceptable ranges are a part of ASO! C566-67, ASTM Cl36-71, and ASTM Cll7-o9 requirements.
Later on,,
the licensee indicated that a hole vill
~~
be drilled in the oven, and a calibrated thermometer vill be inserted for verifying the oven temperature."
4 B.
Corrective Stees Taken and Results Achieved On January 16, 1976, in response to questions raised by Mr. Yin during the inspection, the drying oven temperature control setting which had been used for drying aggregate was verified by use of a standard l
thermemeter traceable to the National Bureau of Standards.
It was found that this temperature setting resulted in an oven temperature of 2210F t
l.
which is within the ASDI C-117 and C-136 specified te=perature range of 230 1 90F and within the 212 - 230 F requirement of ASTM 566.
Based on.
the previous information, the drying oven controls were reset and a new temperature control setting was selected resulting in a drying oven l
temperature of 2260F.
i C.
Corrective Actior Ta'<en to Avoid Further Items of Honecmeliance b
V In lieu of the con.nitment made to Mr. Yin "that a hole vill be drilled in the oven, and a calibrated thermemeter vill be inserted for verifying the oven temperature," it has been decided to reverify the temperature i
i.
_._.,....m.,
E, p.,.
._,e_.
wv
.~ -,
..,m-,..
.. -..w..,r~,-.m
.,,w v
.. ~
~
4 2
m control every three months.
In order to assure this reverification, the oven in question has been included in the U.S. Testing Company's Equipment Calibration frequency list.
In order to preclude repetition of similar instances of noncom-pliance at the U.S. Testing Laboratory facility, each piece of equip-ment at the facility was reviewed to determine it it should be included in the Equipment Calibration frequency list.
This review is ce=plete and the list has been approved by Bechtel.
D.
Date when Full Comeliance vill be Achieved Implementation of the corrective actions described in Sections "I-B" and "I-C" above is complete.
II.
LACK OF MEASURES TO IDENTIFY NONCONFORMING AGGREGATE A.
Descrintions of the Ncnce=nliance (1)
From Page 2 of Inspection Report #76-01:
" Contrary to 10 CFR Part 50, Appendix B, Criterien XV, measures have not been established to identify nonconforming aggregate."
(2)
Frc= Pages 8 and 9 (Ite= No. 7) of Inspection Report #76-01:
"As the inspector drove by the batch plant, two piles of improperly shaped aggregates were observed.
It was later revealed that these are nonconforming materials unfit for safety related structural concrete mix use.
Reviewing the Champicn, Inc. C,A Manual for Ready Mix Concrete, dated June 5, 1975, Contract No. 7220-C-230, and Centract No. R-373 4, the inspector considered that some provisions for noncenforming material control vere lacking.
These included:
(1) rejected material identification (2) disposition of ncnconfor=in6 materiale,
(3) vording, that removal of =aterial 'as soon as possible', ' as early as possible',
constitutes no specific ceaning and has no implementation value.
Reviewing the batch 7-~ )
plant supervisor's daily leg, the 1 1/2"
('- '
acgregate, approximately 50 yards, was re-jected on December 23, 197h.
The second
/mi 3
(J pile of nonconfor=ing aggregates, about the sa:e size as the first pile, vas told to be spills and vaste =aterial and no recer:is had been kept. The inspecter censidered that the handling of the concenfer=ing =cterial has not =et the CA rcerc= rec.uire=ent."
r 3.
Corrective Stens Taken end Results Achieved In respense to questions raised by Mr. Yin during the tnspection, and in order to i= prove control cf neneenfor=ing =cterial, =etal signs reading "FIJICT*:.D DC NOT USE" vare placed in the tvc riles of ncn-confo=ing aggregate. This vas cc=pleted en January 19, 1976.
In order to further i= prove centrol of these =aterials, the tvc piles in questica vere re=oved frc= the batch plant area at the Midla=d Plant site to a locatien sufficiently re=cte frc= acceptable aggregate to preclude use and the signs =entioned above vere placed in frent of the relocated piles.
This relocatica vas ce=plete:1 by Januarf 30, 1976.
Sese actions ad:le:i to the existing centrels -t.ich have precluded the x
use of this cenconfe=ing aggregate.
t
~.)
C.
Cc-rective Action Taken to Avoid Fu-ther Iters of Hence--lia ce In respense to this ncnce=pliance, the cern t=ents in the Chehpicn, Inc. QA Manual relative to centrol of ncncenfer.ing =aterial vere -
revieved.
As a result of this reviev, it was decided to =cdiff the c- =it=ents in the Cha=picn, Inc. QA Manual.
In sr---wf, these revised cen=it=ents vill =ake a distinction between "cencenfo =ing" asregate fer which the dispcsition has net been deter =ine:i and " Rejected" aggregate.
"Nenconfor=ing" aggregate vill te centrolled to prevent inadvertent use by placing a sign, identifying the =aterial as ncnccc-fc =ing, in the aggregate (when the ncncenfc =ing age-egate is a portica of a larger pile of aggregate, the limits of the ncncenfer=ing agg egate vill be delineated).
"Rejecte:i" aggregate vill be ecctrelled by either re=cval frc= the Midland Plant site er ty re eval to a clearly designat e:i reject =aterial area en the Midland Flant Site.
ple=enta-tica of these revised ec:=it=ents shoul:1 avcid further si=ilar iters of nonec=pliance.
D.
Date when full Cc=pliance vill te Achieved Cha=pien is in the precess of revising its CA Manual.
Eevisien of the Manual and approval for i=plementaticn at the Midland Plant site is c.aticipated to be ce=plete by March C2,1976.
sv 9
e y
w
--n-
I
)
k m
%J III.
FAILURE TO IMPLE4ENT COMMITMENTS FOR THE DISPOSITION OF NONCONFORMING AGGREGATE A.
Descriptionsor the Noncomoliance (1) From Page 2 of Inspection Report #76,01:
" Contrary to 10 CFR Part 50, Appendix 3, Criterion V and the Champion, Inc. QA progra= =anual, Appendix A, Paragraph 12, nonconformance aggregates were not disposed of as required."
(2)
Supplemental information from Pages 8 and 9 of Inspection Report #76-01 is reproduced in Section "II-A-(2)" above.
B.
Corrective Steps Taken and Results Achieved In response to this item of nonce =pliance, the ce==it=ents of the Champion QA Manual for re= oval frc= the site of nonconforming material "as soon as possible" and the recordin5 of spilled and vaste =aterial re= oval in the supervisor's daily lo6 vere reviewed and found to be s,/
unnecessary cc==itments for the centrol of nonconforming aggregate.
In lieu of i=plementing these co==itments, the aggregate vas centrolled as discussed in Section "II-3" above.
C.
Corrective Action Taken to Avoid Further Items of Honecerliance As is discussed in Section "II-C" above, the Cha= pion QA Manual cc==it=ents relative to control of nonconforming =aterial vere reviewed and are being revised.
This revision vill no longer refer to re= oval "as soon as pessible" as a control mechanis= for nonconforming material.
It vill also no lenger require the logging of spilled and vaste aggregate removal to the reject aggrecate pile.
In order to avoid future failures to implement QA Manual ce==itments, Champien has been requested to train affected personnel in the implementation of the revised QA Manual l
cc=mitments.
D.
Date when full Comnliance vill be Achieved Revisien of the Cha= pion QA Manual and completion of training relatin6 to the revised co==it=ents is anticipated to be ec=plete by March 22, 1976.
A k
l ss HWS/jmb 2/27/76 l
l
_._